This manual covers a comprehensive range of Yamaha outboard motors manufactured between 1999 and 2002, including models from 2 HP up to 90 HP, as well as specialized jet drive and E-series variants. These engines are engineered for reliability and performance, making them suitable for a wide array of boating applications, from recreational use to professional needs. The robust construction and innovative design of these Yamaha outboards ensure dependable operation and longevity when properly maintained.
This guide is designed to assist both novice owners and experienced technicians in maintaining and repairing their Yamaha outboard engines. It provides detailed instructions for routine maintenance, troubleshooting common issues, and performing complex repairs. The manual includes essential technical specifications, safety guidelines, and step-by-step procedures for all major engine systems, including the fuel, ignition, electrical, power head, gearcase, and tilt/trim systems. By following the information contained within, users can ensure their engines remain in optimal condition, maximizing performance and minimizing downtime.
Models Covered:
Yamaha 2 HP (1999-2002)
Yamaha 3 HP (1999-2002)
Yamaha 4 HP (1999-2002)
Yamaha 5 HP (1999-2002)
Yamaha 6 HP (1999-2002)
Yamaha 8 HP (1999-2002)
Yamaha 9.9 HP (1999-2002)
Yamaha 15 HP (1999-2002)
Yamaha 20 HP (1999-2002)
Yamaha 25 HP (Two-Cylinder) (1999-2002)
Yamaha 25 HP (Three-Cylinder) (1999-2002)
Yamaha 28 JET (1999-2002)
Yamaha 30 HP (1999-2002)
Yamaha 35 JET (1999-2002)
Yamaha 40 HP (1999-2002)
Yamaha 50 HP (1999-2002)
Yamaha 60 HP (1999-2002)
Yamaha E60 (1999-2002)
Yamaha 65 JET (1999-2002)
Yamaha 70 HP (1999-2002)
Yamaha 75 HP (1999-2002)
Yamaha E75 (1999-2002)
Yamaha 80 HP (1999-2002)
Yamaha 90 HP (1999-2002)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial number and model identification / Engine operation / Fasteners / Shop supplies / Galvanic corrosion / Propellers / Basic tools / Special tools / Precision measuring tools / Electrical system fundamentals / Basic mechanical skills / Engine identification codes / Technical abbreviations / Metric tap and drill sizes / Conversion formulas / Specifications
CHAPTER TWO / TROUBLESHOOTING
Preliminary inspection / Operating requirements / Starting difficulty / Fuel system / Starting system / Charging system / Fuse and wire harness / Warning system / Oil injection system / Ignition system / Tilt and trim system / Power head / Cooling system / Gearcase / Starting system troubleshooting / Fuel system troubleshooting / Ignition system troubleshooting / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Power head lubrication / Engine oil recommendation / Premix models / Oil injected models / Oil injection system inspection and maintenance / Oil level check and filling / Gearcase lubrication / Gearcase lubricant change / Jet drive lubrication / Throttle and shift linkage lubrication / Swivel shaft and tilt tube lubrication / Tilt lock and reverse lock mechanism lubrication / Bearing carrier lubrication / Maintenance / Propeller shaft and propeller maintenance and service / Cooling system maintenance / Flushing cooling system / Battery service / Starter motor service / Fuel system / Fuel requirements / Fuel additives / Fuel filter service / Fuel hoses, clamps and valves / Corrosion prevention / Storage / Fitting out / Submersion / Tune-up / Compression test / Spark plugs / Timing adjustment / Carburetor adjustment / Engine break-in / Specifications / Maintenance schedule / Fluid capacities / Oil and fuel mixing rates / Spark plug specifications
CHAPTER FOUR / TIMING, SYNCHRONIZATION AND ADJUSTMENT
Timing, synchronization and adjustments / Test propellers / Wide open throttle speed / Specification
CHAPTER FIVE / FUEL SYSTEM
Fuel system safety / Fuel system component service / Carburetor / Reed housing/intake manifold / Recirculation system / Specifications
CHAPTER SIX / IGNITION AND ELECTRICAL SYSTEMS
Battery / Starting system components / Starter motor / Charging system components / Ignition system components / Warning system components / Specifications
CHAPTER SEVEN / POWER HEAD
Service considerations / Power head break-in / Service recommendations / Lubricants, sealants and adhesives / Fasteners and torque / Power head removal/installation / Flywheel removal/installation / Power head disassembly / Power head components cleaning and inspection / Power head assembly / Specifications
CHAPTER EIGHT / GEARCASE
Gearcase operation / Propeller / Gearcase removal/installation / Water pump / Gearcase disassembly/assembly / Sacrificial anodes / Component inspection / Gearcase pressure test / Specifications
CHAPTER NINE / JET DRIVE
Jet drive operation / Jet drive repair / Specifications
CHAPTER TEN / MANUAL STARTER
Repair / Specifications / Starter rope length
CHAPTER ELEVEN / TILT/TRIM AND MIDSECTION
Manual tilt system removal and installation / Power tilt/trim system removal/installation / Tilt/trim relay replacement / Tilt/trim sender replacement / Electric trim motor removal/installation / Tilt/trim system electric motor repair / Manual release valve removal and installation / Hydraulic system filling and bleeding / Midsection / Specifications
CHAPTER TWELVE / OIL INJECTION SYSTEM
System operation / Oil level sensor removal/installation / Oil reservoir removal/installation / Oil hoses and check valves / Oil pump / Driven gear / Bleeding air from the system / Specifications / Oil reservoir capacity / Oil pump identification
CHAPTER THIRTEEN / REMOTE CONTROL
Neutral throttle operation / Throttle/shift cable removal/installation / Remote control / Specifications
INDEX
WIRING DIAGRAMS
Models Covered:
Yamaha 2 HP (1999-2002)
Yamaha 3 HP (1999-2002)
Yamaha 4 HP (1999-2002)
Yamaha 5 HP (1999-2002)
Yamaha 6 HP (1999-2002)
Yamaha 8 HP (1999-2002)
Yamaha 9.9 HP (1999-2002)
Yamaha 15 HP (1999-2002)
Yamaha 20 HP (1999-2002)
Yamaha 25 HP (Two-Cylinder) (1999-2002)
Yamaha 25 HP (Three-Cylinder) (1999-2002)
Yamaha 28 JET (1999-2002)
Yamaha 30 HP (1999-2002)
Yamaha 35 JET (1999-2002)
Yamaha 40 HP (1999-2002)
Yamaha 50 HP (1999-2002)
Yamaha 60 HP (1999-2002)
Yamaha E60 (1999-2002)
Yamaha 65 JET (1999-2002)
Yamaha 70 HP (1999-2002)
Yamaha 75 HP (1999-2002)
Yamaha E75 (1999-2002)
Yamaha 80 HP (1999-2002)
Yamaha 90 HP (1999-2002)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial number and model identification / Engine operation / Fasteners / Shop supplies / Galvanic corrosion / Propellers / Basic tools / Special tools / Precision measuring tools / Electrical system fundamentals / Basic mechanical skills / Engine identification codes / Technical abbreviations / Metric tap and drill sizes / Conversion formulas / Specifications
CHAPTER TWO / TROUBLESHOOTING
Preliminary inspection / Operating requirements / Starting difficulty / Fuel system / Starting system / Charging system / Fuse and wire harness / Warning system / Oil injection system / Ignition system / Tilt and trim system / Power head / Cooling system / Gearcase / Starting system troubleshooting / Fuel system troubleshooting / Ignition system troubleshooting / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Power head lubrication / Engine oil recommendation / Premix models / Oil injected models / Oil injection system inspection and maintenance / Oil level check and filling / Gearcase lubrication / Gearcase lubricant change / Jet drive lubrication / Throttle and shift linkage lubrication / Swivel shaft and tilt tube lubrication / Tilt lock and reverse lock mechanism lubrication / Bearing carrier lubrication / Maintenance / Propeller shaft and propeller maintenance and service / Cooling system maintenance / Flushing cooling system / Battery service / Starter motor service / Fuel system / Fuel requirements / Fuel additives / Fuel filter service / Fuel hoses, clamps and valves / Corrosion prevention / Storage / Fitting out / Submersion / Tune-up / Compression test / Spark plugs / Timing adjustment / Carburetor adjustment / Engine break-in / Specifications / Maintenance schedule / Fluid capacities / Oil and fuel mixing rates / Spark plug specifications
CHAPTER FOUR / TIMING, SYNCHRONIZATION AND ADJUSTMENT
Timing, synchronization and adjustments / Test propellers / Wide open throttle speed / Specification
CHAPTER FIVE / FUEL SYSTEM
Fuel system safety / Fuel system component service / Carburetor / Reed housing/intake manifold / Recirculation system / Specifications
CHAPTER SIX / IGNITION AND ELECTRICAL SYSTEMS
Battery / Starting system components / Starter motor / Charging system components / Ignition system components / Warning system components / Specifications
CHAPTER SEVEN / POWER HEAD
Service considerations / Power head break-in / Service recommendations / Lubricants, sealants and adhesives / Fasteners and torque / Power head removal/installation / Flywheel removal/installation / Power head disassembly / Power head components cleaning and inspection / Power head assembly / Specifications
CHAPTER EIGHT / GEARCASE
Gearcase operation / Propeller / Gearcase removal/installation / Water pump / Gearcase disassembly/assembly / Sacrificial anodes / Component inspection / Gearcase pressure test / Specifications
CHAPTER NINE / JET DRIVE
Jet drive operation / Jet drive repair / Specifications
CHAPTER TEN / MANUAL STARTER
Repair / Specifications / Starter rope length
CHAPTER ELEVEN / TILT/TRIM AND MIDSECTION
Manual tilt system removal and installation / Power tilt/trim system removal/installation / Tilt/trim relay replacement / Tilt/trim sender replacement / Electric trim motor removal/installation / Tilt/trim system electric motor repair / Manual release valve removal and installation / Hydraulic system filling and bleeding / Midsection / Specifications
CHAPTER TWELVE / OIL INJECTION SYSTEM
System operation / Oil level sensor removal/installation / Oil reservoir removal/installation / Oil hoses and check valves / Oil pump / Driven gear / Bleeding air from the system / Specifications / Oil reservoir capacity / Oil pump identification
CHAPTER THIRTEEN / REMOTE CONTROL
Neutral throttle operation / Throttle/shift cable removal/installation / Remote control / Specifications
INDEX
WIRING DIAGRAMS
